Operators Manual PowerWave 455m

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IM762-C
POWER WAVE 455 M
October, 2006
™
For use with machines having Code Numbers: 10942, 11057, 11152, 11311
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
IEC 60974-1
OPERATOR’S MANUAL
Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting, FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
5.a. Welding may produce fumes and gases
the following equipment:
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
fumes and gases. When welding, keep
• DC Manual (Stick) Welder.
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode,
welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic
ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”.
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical
which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection
low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded.
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical
respirator may be required. Additional precautions are
(earth) ground.
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace by various factors including proper use and positioning of
damaged insulation. the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
3.g. Never dip the electrode in water for cooling. exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
3.h. Never simultaneously touch electrically “hot” parts of OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect form phosgene, a highly toxic gas, and other irritating prod-
yourself from a fall should you get a shock. ucts.
3.j. Also see Items 6.c. and 8. 5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique: 8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains. des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on câbles jusqu’à ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans 9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse. galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement. 10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir. chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines. 11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de voir le code “Code for safety in welding and cutting” CSA
courant pour soudage semi-automatique, ces precautions Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I’installation et l’entretien du poste seront
l‘arc. effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l’huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. ‘93
zones où l’on pique le laitier.
v v
for selecting a QUALITY product by Lincoln Electric. We want you

Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi TABLE OF CONTENTS vi
Page
Installation .......................................................................................................Section A
Technical Specifications - POWER WAVE 455M .................................................A-1
Safety Precautions.................................................................................................A-2
Select Suitable Location ........................................................................................A-2
Lifting...............................................................................................................A-2
Stacking ..........................................................................................................A-2
Machine Grounding ...............................................................................................A-2
High Frequency Protection ....................................................................................A-2
Input Connection....................................................................................................A-2
Input Fuse and Supply Wire Considerations .........................................................A-3
Input Voltage Change Over Procedure..................................................................A-3
Electrode and Work Cable Connections................................................................A-3
Cable Inductance, and its Effects on Pulse Welding ............................................A-4
Negative Electrode Polarity ...................................................................................A-4
Voltage Sensing ................................................................................................... A-4
Power Wave to Semi-automatic Power Feed Wire Feeder Interconnections........A-5
System Description................................................................................................A-5
Welding with Multiple Power Waves......................................................................A-6
Control Cable Specifications..................................................................................A-6
Multiple Arc Unsynchronized .................................................................................A-7
I / O Receptacle Specifications..............................................................................A-8
Dip Switch Settings and Locations.................................................................A-8
Control Board Dip Switch ................................................................................A-8
Water Flow Sensor..........................................................................................A-8
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
Graphic Symbols that appear on this machine or in this manual...........................B-2
Definition of Welding Terms...................................................................................B-3
General Description ...............................................................................................B-4
Recommended Processes and Equipment ...........................................................B-4
Required Equipment ..............................................................................................B-4
Limitations..............................................................................................................B-4
Duty Cycle and Time Period ..................................................................................B-4
Case Front Controls ........................................................................................B-5
Nominal Procedures........................................................................................B-6
Fringe Procedures...........................................................................................B-6
Making a Weld ................................................................................................B-6
Welding Adjustment ........................................................................................B-6
Constant Voltage Welding...............................................................................B-7
Pulse Welding .................................................................................................B-8
________________________________________________________________________
Accessories .....................................................................................................Section C
Optional Equipment ...............................................................................................C-1
Factory Installed..............................................................................................C-1
Field Installed..................................................................................................C-1
Compatible Lincoln Equipment .......................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance ............................................................................................D-1
Calibration Specification ........................................................................................D-1
________________________________________________________________________
vii TABLE OF CONTENTS vii
Page
Troubleshooting ..............................................................................................Section E
How to use Troubleshooting Guide .......................................................................E-1
Using the Status LED to Troubleshoot System Problems .....................................E-2
Error Codes For Power Waves..............................................................................E-3
Troubleshooting Guide.............................................................................E-4 thru E-6
________________________________________________________________________
Wiring Diagram ............................................................................................Section F-1
Connection Diagrams ..................................................................................Section F-2
Dimension Print............................................................................................Section F-3
________________________________________________________________________
Parts Lists ....................................................................................................P438 Series
________________________________________________________________________
A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS - POWER WAVE 455M (K2202-1, K2202-3)
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS- OUTPUT INPUT IDLE POWER FACTOR EFFICIENCY
FREQUENCY CONDITIONS CURRENT POWER @ RATED OUTPUT @ RATED
AMPS / VOLTS / DUTY CYCLE AMPS OUTPUT
208/230/460/575V - 60HZ. 450A@38V.100% 58/53/25/22

570A@43V. 60% 82/78/37/31
400 Watts .95 MIN. 88%
400A@36V.100% 49/45/23/18 Max.
200/220/440/575V - 50HZ. 500A@40V. 60% 67/61/31/25
OUTPUT
OPEN CURRENT PULSE PULSE PULSE AND AUXILIARY POWER
CIRCUIT RANGE FREQUENCY VOLTAGE BACKGROUND (CIRCUIT BREAKER PROTECTED)
VOLTAGE AMPS RANGE TIME RANGE
75 VDC 5 - 570A 0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. - 40 VDC AT

3.3 SEC. 10 AMPS
115VAC AT
15* AMPS
PROCESS CURRENT RANGE (DC) CURRENT
MIG/MAG 50-570 Average Amps
FCAW 40-570 Average Amps
SMAW 30-570 Average Amps
GTAW 15-500 Average Amps
Pulse 5-750 Peak Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT TYPE 75°C TYPE 75°C TYPE 75°C
VOLTAGE / COPPER WIRE IN GROUND WIRE IN CON- (SUPER LAG)
FREQUENCY CONDUIT AWG[IEC] DUIT AWG[IEC] SIZES OR BREAKER
SIZES (MM2) (MM2) SIZE (AMPS)
208/50/60HZ 4(25) 6(16) 110

230/50/60HZ 4(25) 6(16) 100
460/50/60HZ 8(10) 10(6) 50
575/50/60HZ 10(6) 10(6) 40
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
26.10 in 19.86 in 32.88 in 286 lbs.
663 mm 505 mm 835 mm 130 kg.
TEMPERATURE RANGES STORAGE TEMPERATURE RANGE

OPERATING TEMPERATURE RANGE -40°C to +40°C
-20°C to +40°C
* Earlier models used 10 amps circuit breaker.
POWER WAVE 455M

SAFETY PRECAUTIONS Read this LIFTING
entire installation section before you start installa- Lift the machine by the lift bail only. The lift bail is
tion. designed to lift the power source only. Do not attempt
to lift the Power Wave with accessories attached to it.
WARNING
STACKING
ELECTRIC SHOCK can kill.
Power Wave machines can be stacked to a maximum
• Only qualified personnel should per- of 3 high.
form this installation.
• Turn the input power OFF at the CAUTION
disconnect switch or fuse box before
working on this equipment. Turn off the input The bottom machine must always be placed on a
power to any other equipment connected to the firm, secure, level surface. There is a danger of
machines toppling over if this precaution is not
welding system at the disconnect switch or fuse taken.
box before working on the equipment.
• Do not touch electrically hot parts.
MACHINE GROUNDING
• Always connect the Power Wave grounding lug
The frame of the welder must be grounded. A ground
(located inside the reconnect input access door)
terminal marked with the symbol is located inside
to a proper safety (Earth) ground.
the reconnect/input access door for this purpose. See
---------------------------------------------------------- your local and national electrical codes for proper
SELECT SUITABLE LOCATION grounding methods.
Do not use Power Waves in outdoor environments.

The Power Wave power source should not be subject- HIGH FREQUENCY PROTECTION
ed to falling water, nor should any parts of it be sub- Locate the Power Wave away from radio controlled
merged in water. Doing so may cause improper oper- machinery.
ation as well as pose a safety hazard. The best prac-
tice is to keep the machine in a dry, sheltered area. CAUTION
Do not mount the Power Wave 455M over com-
The normal operation of the Power Wave may
bustible surfaces. Where there is a combustible sur-
adversely affect the operation of RF controlled
face directly under stationary or fixed electrical equip-
equipment, which may result in bodily injury or
ment, that surface shall be covered with a steel plate
damage to the equipment.
at least .060" (1.6mm) thick, which shall extend not
less than 5.90" (150mm) beyond the equipment on all
sides. INPUT CONNECTION
Place the welder where clean cooling air can freely cir- WARNING
culate in through the rear louvers and out through the
case sides and bottom. Dirt, dust, or any foreign mater- Only a qualified electrician should
ial that can be drawn into the welder should be kept at connect the input leads to the Power
a minimum. Do not use air filters on the air intake Wave. Connections should be made
because the air flow will be restricted. Failure to in accordance with all local and
observe these precautions can result in excessive national electrical codes and the
operating temperatures and nuisance shutdowns. connection diagram located on the
inside of the reconnect/input access door of the
Machines are equipped with F.A.N. (fan as needed) machine. Failure to do so may result in bodily
circuitry. The fan runs whenever the output is enabled, injury or death.
whether under loaded or open circuit conditions. The
fan also runs for a period of time (approximately 5 min- -------------------------------------------------------------
utes) after the output is disabled, to ensure all compo- Use a three-phase supply line. A 1.75 inch (45 mm)
nents are properly cooled. diameter access hole for the input supply is located on
If desired, the F.A.N. feature can be disabled (causing the the upper left case back next to the input access door.
fan to run whenever the power source is on). To disable Connect L1, L2, L3 and ground according to the Input
F.A.N., connect leads 444 and X3A together at the output Supply Connection Diagram decal located on the
of the solid state fan control relay, located on the back of inside of the input access door or refer to Figure A.1
the Control PC board enclosure. (See Wiring Diagram) on the following page.
POWER WAVE 455M
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

INPUT SUPPLY CONNECTION DIAGRAM
S25198
W / L3 VOLTAGE = 200-208V
WARNING 200-208V
V / L2 CR1
. Disconnect input power before
220-230V
.
inspecting or servicing machine.
Do not operate with covers
U / L1
440-460V 'A'
removed.
ELECTRIC . 550-575V
Do not touch electrically live parts.
SHOCK . Only qualified persons should install,
CAN KILL use or service this equipment.
VOLTAGE =220-230V VOLTAGE = 440-460V VOLTAGE = 550-575V

200-208V 200-208V 200-208V
220-230V 220-230V 220-230V
440-460V 'A' 440-460V 'A' 440-460V 'A'
550-575V 550-575V 550-575V
XA
NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to
do so will result in damage to the machine.
INPUT FUSE AND SUPPLY WIRE ELECTRODE AND WORK CABLE
CONSIDERATIONS
CONNECTIONS
Refer to the Technical Specifications at the beginning Connect a work lead of sufficient size and length (Per
of this Installation section for recommended fuse and Table 1) between the proper output terminal on the
wire sizes. Fuse the input circuit with the recommend- power source and the work. Be sure the connection to
ed super lag fuse or delay type breakers (also called the work makes tight metal-to-metal electrical contact.
“inverse time” or “thermal/magnetic” circuit breakers). To avoid interference problems with other equipment
Choose an input and grounding wire size according to and to achieve the best possible operation, route all
local or national electrical codes. Using fuses or circuit cables directly to the work and wire feeder. Avoid
breakers smaller than recommended may result in excessive lengths and do not coil excess cable.
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents. Minimum work and electrode cable sizes are as follows:
TABLE A.1
INPUT VOLTAGE CHANGE OVER (FOR (Current (60% Duty Cycle) MINIMUM COPPER
MULTIPLE INPUT VOLTAGE WORK CABLE SIZE AWG
MACHINES ONLY) Up To-100 Ft. Length (30 m)
Welders are shipped connected for the highest input 400 Amps 2/0 (67 mm2)
voltage listed on the rating plate. To move this con- 500 Amps 3/0 (85 mm2)
nection to a different input voltage, see the diagram 600 Amps 3/0 (85 mm2)
located on the inside of the input access door. If the
main reconnect switch or link position is placed in the NOTE: K1796 coaxial welding cable is recommended
wrong position, the welder will not produce output to reduce the cable inductance in long cable lengths.
power. This is especially important when Pulse welding up to
350 amps.
If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in a CAUTION
position higher than the applied line voltage, the When using inverter type power sources like the
welder may not come on at all. If the Auxiliary (A) lead Power Waves, use the largest welding (electrode
is placed in a position lower than the applied line volt- and work) cables that are practical. At least 2/0 (67
age, the welder will not come on, and the two circuit mm2) copper wire - even if the average output cur-
breakers or fuses in the reconnect area will open. If rent would not normally require it. When pulsing,
this occurs, turn off the input voltage, properly connect the pulse current can reach very high levels.
the (A) lead, reset the breakers, and try again. For Voltage drops can become excessive, leading to
machines equipped with a fuse in the reconnect area, poor welding characteristics, if undersized weld-
turn off the input voltage and replace the fuse with the ing cables are used.
spare fuse that is attached to the reconnect switch pin. ------------------------------------------------------------------------
POWER WAVE 455M
CABLE INDUCTANCE, AND ITS EFFECTS For additional Safety information regarding the elec-
ON PULSE WELDING trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
For Pulse Welding processes, cable inductance will
Instruction Manuals.
cause the welding performance to degrade. For the
total welding loop length less than 50 ft.(15.24m), tradi-
tional welding cables may be used without any effects CAUTION
on welding performance. For the total welding loop
Excessive voltage drops caused by poor work
length greater than 50 ft.(15.24m)), the K1796 Coaxial
piece connections often result in unsatisfactory
Welding Cables are recommended. The welding loop
welding performance.
length is defined as the total of electrode cable length
------------------------------------------------------------------------
(A) + work cable length (B) + work length (C) (See
Figure A.3). NEGATIVE ELECTRODE POLARITY
FIGURE A.3 When negative electrode polarity is required, such as
in some Innershield applications, switch the output
POWER
WAVE
connections at the power source (electrode cable to
A the negative (-) stud, and work cable to the positive (+)
stud).
C
WORK When operating with electrode polarity negative the

B "Electrode Sense Polarity" DIP switch must be set to
For long work piece lengths, a sliding ground should the "Negative" position on the Wire Drive Feed Head
be considered to keep the total welding loop length PC Board. The default setting of the switch is positive
less than 50 ft.(15.24m). (See Figure A.4.) electrode polarity. Consult the Power Feed instruction
manual for further details.
FIGURE A.4
FIGURE A.4
POWER
WAVE
A A VOLTAGE SENSING
The best arc performance occurs when the Power
C WORK C
Waves have accurate data about the arc conditions.
B B Depending upon the process, inductance within the
SLIDING WORK
electrode and work lead cables can influence the
K1796 COAXIAL CABLE apparent voltage at the studs of the welder. Voltage
MEASURE FROM END
sense leads improve the accuracy of the arc conditions
OF OUTER JACKET OF and can have a dramatic effect on performance.
CABLE
Sense Lead Kits (K940-10, -25 or -50) are available for
this purpose.
Output connections on some Power Waves are made
via 1/2-13 threaded output studs located beneath the CAUTION
spring loaded output cover at the bottom of the case If the voltage sensing is enabled but the sense
front. leads are missing, improperly connected, or if the
electrode polarity switch is improperly configured,
Most welding applications run with the electrode being extremely high welding outputs may occur.
positive (+). For those applications, connect the elec- ------------------------------------------------------------------------
trode cable between the wire feeder and the positive
(+) output stud on the power source (located beneath The ELECTRODE sense lead (67) is built into the con-
the spring loaded output cover near the bottom of the trol cable, and is automatically enabled for all semi-
case front). Connect the other end of the electrode automatic processes. The WORK sense lead (21) con-
cable to the wire drive feed plate. The electrode cable nects to the Power Wave at the four pin connector
lug must be against the feed plate. Be sure the con- located underneath the output stud cover. By default
nection to the feed plate makes tight metal-to-metal the WORK voltage is monitored at the output stud in
electrical contact. The electrode cable should be sized the Power Wave 455M. For more information on the
according to the specifications given in the work cable WORK sense lead (21), see "Work Voltage Sensing”
connections section. Connect a work lead from the in the following paragraph.
negative (-) power source output stud to the work
piece. The work piece connection must be firm and All constant current processes sense the voltage at the
secure, especially if pulse welding is planned. output studs of the POWER WAVE-455M by default.
POWER WAVE 455M

Enable the voltage sense leads as follows: Electrode Voltage Sensing
TABLE A.2 Enabling or disabling electrode voltage sensing is
Process Electrode Voltage Work Voltage automatically configured through software. The 67
Sensing 67 lead * Sensing 21 lead electrode sense lead is internal to the cable to the
GMAW 67 lead required 21 lead optional wire feeder and always connected when a wire feeder
GMAW-P 67 lead required 21 lead optional is present.
FCAW 67 lead required 21 lead optional
GTAW Voltage sense at studs Voltage sense at studs CAUTION
GMAW Voltage sense at studs Voltage sense at studs
SAW 67 lead required 21 lead optional Important: The electrode polarity must be config-
CAC Voltage sense at studs Voltage sense at studs ured at the feed head for all semi-automatic
processes. Failure to do so may result in extreme-
* The electrode voltage 67 sense lead is integral to ly high welding outputs.
the control cable to the wire feeder. ------------------------------------------------------------------------
POWER WAVE TO SEMI-AUTOMAT-
Work Voltage Sensing
The standard Power Wave 455M’s default to the work IC POWER FEED WIRE FEEDER
stud (work sense lead disabled) INTERCONNECTIONS
For processes requiring work voltage sensing, con- The Power Wave 455M and semi-automatic POWER
nect the (21) work voltage sense lead (K940) from the FEED family communicate via a 5 conductor control
Power Wave work sense lead receptacle to the work cable (K1543). The control cable consists of two power
piece. Attach the sense lead to the work piece as leads, one twisted pair for digital communication, and
close to the weld as practical, but not in the return cur- one lead for voltage sensing. The cables are designed to
rent path. Enable the work voltage sensing in the be connected end to end for ease of extension. The out-
Power Wave as follows: put receptacle on the Power Wave 455M is located
beneath the spring loaded output cover at the bottom of
WARNING the case front. The input receptacle on the Power Feed
is typically located at the back of the feeder, or on the
• Do not touch electrically live bottom of the user interface.
parts or electrodes with your
skin or wet clothing. For convenience sake, the electrode and control cables
can be routed behind the left or right strain reliefs (under
• Insulate yourself from the work
the spring loaded output cover), and along the channels
and ground. formed into the base of the Power Wave, out the back of
• Always wear dry insulating gloves. the channels, and then to the wire feeder.
----------------------------------------------------------- Due to the flexibility of the platform the configuration may

1. Turn off power to the power source at the discon- vary. The following is a general description of the sys-
nect switch. tem.
2. Remove the front cover from the power source. SYSTEM DESCRIPTION
3. The control board is on the left side of The Power Wave 455M and Power Feed M family of
the power source. Locate the 8-position products utilize a digital communication system called
8
DIP switch and look for switch 8 of the ArcLink. Simply put, ArcLink allows large amounts of
7
DIP switch. information to be passed at very high speeds between

6
components (nodes) in the system. The system requires

5
only two wires for communication, and because of its

4
4. Using a pencil or other small object,

3
slide the switch right to the OFF posi- bus-like structure, the components may be connected to
2
the network in any order, thus simplifying the system set-

tion if the work sense lead is NOT con-
1
up.
nected. Conversely, slide the switch to
O
N
the ON position if the work sense lead

Each "system" must contain only one power source.
is present.
The number of wire feeders is determined by the type
of wire feeder. Refer to the wire feeder instruction
5. Replace the cover and screws. The PC board will
manual for details
“read” the switch at power up, and configure the
work voltage sense lead appropriately.
POWER WAVE 455M

CONFIGURING THE SYSTEM If a system can not be “Auto Mapped” then the status
light on the power source will blink green fast and the
For codes below 11100, consult the semi-automatic welder output will be disabled. If a system is not
Power Feed instruction manual for configuration infor- “Auto-mappable”, then consult the instruction manual
mation about DIP switch settings. for the accessory being used for configuration infor-
mation about DIP switch settings, or consult your local
For codes above 11100, the power source will “Auto Lincoln sales representative.
Map” the system eliminating most of the need to set
DIP switches to configure the system.
SINGLE HEAD FEEDER DUAL HEAD FEEDER

UP TO 4 FEEDERS
ALLOWED
POWER WAVE POWER WAVE

455M FEED HEAD
455M
SINGLE HEAD BOOM FEEDER

UP TO 4 FEED HEADS
ALLOWED
POWER WAVE
455M
FH 1
SINGLE HEAD BOOM FEEDER
POWER WAVE 455M

ROBOT
WIRE
PF-10R
PLC CONTROLLER
ANALOG INTERFACE DRIVE
MODULE
etc.
POWER WAVE 455M

ALTERNATE HARD AUTOMATIC APPLICATION
(using a UI, WD Module, and PF-10R)
POWER WAVE 455M

PF-10R
WIRE
DRIVE
MODULE
(FH1)
COMBINATION HARD AUTOMATION APPLICATION

(w/ Semi-Auto, WD Module, and PF-10R)
POWER WAVE 455M

WIRE
PF-10R
DRIVE
MODULE
DUAL HEAD
(FH1)
System that is NOT "Auto Mappable"
DUAL HEAD BOOM FEEDER

(using two single heads)
POWER WAVE
455M DUAL HEAD
FH-1 FH-2
In this case the individual feed heads need to be assigned to the dual head control and the PW455 auto mapping
disabled and the Equipment Groups set on (See Figure A-6). (See the Feeder documentation for information on
setting the feeder DIP switches)
POWER WAVE 455M
WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS

WAVES It is recommended that genuine Lincoln control cables
be used at all times. Lincoln cables are specifically
designed for the communication and power needs of
CAUTION the Power Wave / Power Feed system.
Special care must be taken when more than one
Power Wave is welding simultaneously on a single CAUTION
part. Arc blow and arc interference may occur or
be magnified. The use of non-standard cables, especially in
------------------------------------------------------------------------ lengths greater than 25 ft.(7.62), can lead to com-
munication problems (system shutdowns), poor
Each power source requires a work lead from the motor acceleration (poor arc starting) and low
work stud to the welding fixture. Do not combine all of wire driving force (wire feeding problems).
the work leads into one lead. The welding travel direc- ------------------------------------------------------------------------
tions should be in the direction moving away from the The K1543 series of control cables can be connected
work lead as shown below. Connect all of the work end to end for ease of extension. Do not exceed more
sense leads from each power source to the work than 100 feet (30.5 m) total control cable length.
piece at the end of the weld.
For the best results when pulse welding, set the wire
size and wire feed speed the same for all the Power
Waves. When these parameters are identical, the
pulsing frequency will be the same, helping to stabilize
the arcs.
Every welding gun requires a separate shielding gas

regulator for proper flow rate and shielding gas cover-
age.
Do not attempt to supply shielding gas for two or more

guns from only one regulator.
If an anti-spatter system is in use then each gun must

have its own anti-spatter system. (See Figure A.2)
FIGURE A.2
TWO POWER WAVES POWER WAVE
POWER WAVE POWERWAVE
POWERWAVE
- +
- +
Travel
Direction
Connect All Work

Sense Leads at the En
of the Joint
Connect All Welding

Work Leads at the
Beginning of the Joint
POWER WAVE 455M
MULTIPLE ARC UNSYNCHRONIZED SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES
POWER WAVE 455M

I / O RECEPTACLE SPECIFICATIONS switch 7 auto mapping
TABLE 3 off(default) auto mapping enable
WIRE FEEDER RECEPTACLE S1 on auto mapping disabled
PIN LEAD# FUNCTION
A 53 Communication Bus L
B 54 Communication Bus H
C 67A Electrode Voltage Sense switch 8 work sense lead
D 52 0vdc *off(default) work sense lead not connected
E 51 +40vdc on work sense lead connected
TABLE 4 * The Power Wave 455M does not come supplied with a
work sense lead.
VOLTAGE SENSE RECEPTACLE S2
PIN LEAD# FUNCTION
3 21A Work Voltage Sense
FIGURE A.5
TABLE 5 CONTROL BOARD (DIP Switch Location)

RS232 RECEPTACLE S3
PIN LEAD# FUNCTION
2 253 RS232 Receive
3 254 RS232 Transmit
4 # S3 Pin5
5 # S3 Pin4
6 ## S3 Pin20
20 ## S3 Pin6
7 251 RS232 Common
DIP SWITCH SETTINGS AND LOCATIONS
DIP switches on the P.C. Boards allow for custom WATER FLOW SENSOR
configuration of the Power Wave. To access the DIP Water cooled guns can be damaged very quickly if
switches: they are used even momentarily without water flowing.
• Turn off power at the disconnect switch. A water flow sensor is recommended for those water
• Remove the top four screws securing the front coolers that do not have an integral flow sensor.
access panel. Recommended practice is to install a water flow sen-
• Loosen, but do not completely remove, the bottom sor such as K1536-1 on the water return line of the
two screws holding the access panel. torch. When fully integrated into the welding system,
• Open the access panel, allowing the weight of the the sensor will prevent welding if no water flow is pre-
panel to be carried by the bottom two screws. Make sent.
sure to prevent the weight of the access panel from
hanging on the harness.
• Adjust the DIP switches as necessary.
FIGURE A.6
• Replace the panel and screws, and restore power.
CONTROL BOARD DIP SWITCH:

switch 1 = reserved for future use
switch 3 = equipment group 1 selcted (default=off)
switch 4 = equipment group 2 selcted (default=off)
switch 7 = auto mapping
switch 8 = work sense lead
(See Figure A.6 for Dual Head Boom Feeder)
POWER WAVE 455M

B-1 OPERATION B-1
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
WARNING

• Unless using cold feed feature, when
feeding with gun trigger, the electrode
and drive mechanism are always elec-
trically energized and could remain
energized several seconds after the
welding ceases.
• Do not touch electrically live parts or electrodes
with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dan-

gerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire

or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
ARC RAYS can burn.

• Wear eye, ear, and body protection.
Observe additional guidelines detailed in the begin-

ning of this manual.
POWER WAVE 455M

B-2 OPERATION B-2
GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL
INPUT POWER SMAW
ON GMAW
OFF FCAW
HIGH TEMPERATURE GTAW
MACHINE STATUS U0 OPEN CIRCUIT

VOLTAGE
CIRCUIT BREAKER U1 INPUT VOLTAGE
WIRE FEEDER U2 OUTPUT VOLTAGE
POSITIVE OUTPUT I1 INPUT CURRENT
NEGATIVE OUTPUT I2 OUTPUT CURRENT
3 PHASE INVERTER PROTECTIVE

GROUND
INPUT POWER
THREE PHASE WARNING OR

CAUTION
DIRECT CURRENT
POWER WAVE 455M

B-3 OPERATION B-3
DEFINITION OF WELDING TERMS SMAW
• Shielded Metal Arc welding
NON-SYNERGIC WELDING MODES SW
• Stud Arc Welding
• A Non-synergic welding mode requires all welding
process variables to be set by the operator. SAW
• Submerged Arc Welding
SYNERGIC WELDING MODES
SAW-S
• A Synergic welding mode offers the simplicity of • Submerged Arc Welding-(Series)
single knob control. The machine will select the cor-
rect voltage and amperage based on the wire feed FCAW
speed (WFS) set by the operator. • Flux Core Arc Welding
455M CAC
•455Modular • Carbon Arc Cutting
WFS
• Wire Feed Speed
CC
• Constant Current
CV
• Constant Voltage
GMAW
• Gas Metal Arc welding
GMAW-P
• Gas Metal Arc welding-(Pulse Arc)
GMAW-S
• Gas Metal Arc welding-(Short Circuiting Arc)
GTAW
• Gas Tungsten Arc welding
GTAW-P
• Gas Tungsten Arc welding-(Pulse Arc)
PAW
• Plasma Arc welding
POWER WAVE 455M

B-4 OPERATION B-4
GENERAL DESCRIPTION DeviceNet Interface Module
The Power Wave semi-automatic power source is This module can be used for DeviceNet capability. It
designed to be a part of a modular, multi-process will has a 5 pin sealed mini connector per ANSI
welding system. Depending on configuration, it can B93.55M-1981.
support constant current, constant voltage, and pulse
welding modes. EtherNet/DeviceNet Module
This module includes the DeviceNet and EtherNet
The Power Wave power source is designed to be capability. The DeviceNet uses a 5 pin sealed mini
used with the semi automatic family of Power Feed connector per ANSI B93.55M-1981. The EtherNet
wire feeders, operating as a system. Each component uses a RJ5 connector.
in the system has special circuitry to "talk with" the
other system components, so each component (power RECOMMENDED EQUIPMENT
source, wire feeder, user interface) knows what the
other is doing at all times. These components commu- Power Wave 455M – Semi-Automatic Operation
nicate with ArcLink Semi Automatic Power Waves can only be used with
ArcLink compatible Power Feed semi-automatic wire
The Power Wave 455M is a high performance, digital- feeders and modules. In addition, the Power Feed
ly controlled inverter welding power source capable of semi-automatic wire feeders may require optional
complex, high-speed waveform control. Properly equipment to access certain weld modes in the Power
equipped, it can support the GMAW, GMAW-P, Wave. Other models of Lincoln feeders, or any mod-
FCAW, SMAW, GTAW, and CAC processes. It carries els of non-Lincoln wire feeders, cannot be used.
an output rating of either 450 amps, 38 volts; or 400
amps, 36 volts (both at 100% duty cycle), depending All welding programs and procedures are selected
on input voltage and frequency. through the Power Feed M semi-automatic user inter-
face
RECOMMENDED PROCESSES AND
EQUIPMENT REQUIRED EQUIPMENT
Any ArcLink compatible semi-automatic wire feeding
equipment. Specifically, the semi-automatic Power
RECOMMENDED PROCESSES Feed M family.
The Power Wave 455M can be set up in a number of
configurations, some requiring optional equipment or
welding programs. Each machine is factory prepro- LIMITATIONS
grammed with multiple welding procedures, typically
including GMAW, GMAW-P, FCAW, GTAW, and CAC
WARNING
for a variety of materials, including mild steel, stain-
less steel, cored wires, and aluminum. • The Power Waves are not to be used in outdoor
environments.
The Power Wave 455M is recommended for semi- ------------------------------------------------------------------------
automatic welding with ArcLink compatible equipment • Only ArcLink compatible Power Feed semi-automat-
like the Power Feed M series of feeders. The Power ic wire feeders and users interfaces may be used.
Wave 455M can have a number of modules installed Other Lincoln wire feeders or non-Lincoln wire feed-
that allow the machine to be used in Robotic and hard ers cannot be used.
automation applications.
• Power Wave 455M Output Limitations
Wire Drive Interface Module The Power Wave 455M will support maximum aver-
For Robotic platforms the Wire Drive Control Module age output current of 570 Amps (@ 60% duty cycle)
is required to drive the PF-10R wire drive. This mod- on the standard Power Wave stud.
ule can be factory installed on K2202-3 or field
installed for robotic applications. DUTY CYCLE AND TIME PERIOD
The Power Feed wire feeders are capable of welding
The Wire Drive Control Module is also be equipped at a 100% duty cycle (continuous welding). The power
with a terminal strip for making simple input signal source will be the limiting factor in determining system
connections. It can be used to externally control the duty cycle capability. Note that the duty cycle is based
basic wire drive function. It is divided into three upon a ten minute period. A 60% duty cycle repre-
groups: Trigger group, Cold Inch group, and sents 6 minutes of welding and 4 minutes of idling in a
Shutdown group. ten minute period.
POWER WAVE 455M

B-5 OPERATION B-5
CASE FRONT CONTROLS FIGURE B.1
All operator controls and adjustments are located on
the case front of the Power Wave. (See Figure B.1)
2 3
1. POWER SWITCH: Controls input power to the 1
Power Wave.
2. STATUS LIGHT: A two color light that indicates 6

system errors. Normal operation is a steady green
light. Error conditions are indicated, per table 3. 8
13
NOTE: The Power Wave 455M status light will flash
green, and sometimes red and green, for up to one 12 14
minute when the machine is first turned on. This is a
normal situation as the machine goes through a self
test at power up.
15
TABLE 3
10
Light Meaning 9 4 5
Condition 7 11
Steady Green System OK. Power source communicating normal-
ly with wire feeder and its components.
Blinking Occurs during a reset, and indicates the CASE FRONT LAYOUT
Green Power Wave 455M is mapping (identifying)
each component in the system. Normal for POWER WAVE 455M (NORTH AMERICAN)
first 1-10 seconds after power is turned on,
or if the system configuration is changed 5. 15* AMP AUXILIARY POWER CIRCUIT BREAKER:
during operation Protects 115 volt AC case front receptacle
auxiliary supply.
A l t e r n a t i n g Non-recoverable system fault. If the PS (* Earlier models used 10 amps circuit breaker).
Green and Status light is flashing any combination of
Red red and green, errors are present in the 6. LEAD CONNECTOR S2 (SENSE LEAD)
Power Wave 455M. Read the error code
before the machine is turned off. 7. DIAGNOSTIC CONNECTOR (RS-232)
Error Code interpretation through the Status 8. WIRE FEEDER RECEPTACLE (S1 5-PIN)
light is detailed in the Service Manual.
Individual code digits are flashed in red with 9. NEGATIVE STUD
a long pause between digits. If more than
one code is present, the codes will be sepa- 10. POSITIVE STUD
rated by a green light.
11. AUXILIARY OUTPUT
To clear the error, turn power source off,
and back on to reset. See Troubleshooting 12. 5-PIN DEVICENET CONNECTOR (OPTIONAL)
Section.
Non recoverable hardware fault. Generally 13. ROBOTIC WIRE FEEDER RECEPTACLE
Steady Red
indicates nothing is connected to the Power (OPTIONAL)
Wave 455M wire feeder receptacle. See
Trouble Shooting Section. 14. I/O CONNECTOR (OPTIONAL)
Not applicable. 15. ETHERNET CONNECTOR (OPTIONAL)

Blinking Red
3. HIGH TEMPERATURE LIGHT (thermal overload):
A yellow light that comes on when an over temper-
ature situation occurs. Output is disabled and the
fan continues to run, until the machine cools down.
When cool, the light goes out and output is
enabled.
4. 10 AMP WIRE FEEDER CIRCUIT BREAKER:

Protects 40 volt DC wire feeder power supply.
POWER WAVE 455M

B-6 OPERATION B-6
NOMINAL PROCEDURES WELDING ADJUSTMENTS
The Power Wave is designed to operate with 3/4" All adjustments are made on the system component
electrode stick-out for CV and Pulse processes. known as the User Interface (Control Box), which con-
tains the switches, knobs, and digital displays neces-
FRINGE PROCEDURES sary to control both the Power Wave and a Power
Feed wire feeder. Typically, the Control Box is sup-
Excessively short or long electrode stick-outs may plied as part of the wire feeder. It can be mounted
function only on a limited basis, if at all. directly on the wire feeder itself, the front of the power
source, or mounted separately, as might be done in a
MAKING A WELD welding boom installation.
Because the Control Box can be configured with many

different options, your system may not have all of the
WARNING following adjustments. Regardless of availability, all
The serviceability of a product or structure utiliz- controls are described below. For further information,
ing the welding programs is and must be the sole consult the Power Feed wire feeder instruction manu-
responsibility of the builder/user. Many variables al.
beyond the control of The Lincoln Electric
Company affect the results obtained in applying • WFS / AMPS:
these programs. These variables include, but are In synergic welding modes (synergic CV, pulse
not limited to, welding procedure, plate chemistry GMAW) WFS (wire feed speed) is the dominant con-
and temperature, weldment design, fabrication trol parameter, controlling all other variables. The user
methods and service requirements. The available adjusts WFS according to factors such as weld size,
range of a welding program may not be suitable penetration requirements, heat input, etc. The Power
for all applications, and the build/user is and must Wave then uses the WFS setting to adjust its output
be solely responsible for welding program selec- characteristics (output voltage, output current) accord-
tion. ing to pre-programmed settings contained in the
------------------------------------------------------------------------ Power Wave 455M. In non-synergic modes, the WFS
control behaves more like a conventional CV power
The steps for operating the Power Wave will vary source where WFS and voltage are independent
depending upon the options installed in the user inter- adjustments. Therefore to maintain the arc character-
face (control box) of the welding system. The flexibility istics, the operator must adjust the voltage to compen-
of the Power Wave system lets the user customize sate for any changes made to the WFS.
operation for the best performance.
In constant current modes (stick, TIG) this control
First, consider the desired welding process and the adjusts the output current, in amps.
part to be welded. Choose an electrode material,
diameter, shielding gas and process (GMAW, GMAW- • VOLTS / TRIM:
P, etc.) In constant voltage modes (synergic CV, standard
CV) the control adjusts the welding voltage.
Second, find the program in the welding software that
best matches the desired welding process. The stan- In pulse synergic welding modes (pulse GMAW only)
dard software shipped with the Power Waves encom- the user can change the Trim setting to adjust the arc
passes a wide range of common processes and will length. It is adjustable from 0.500 to 1.500. A Trim set-
meet most needs. If a special welding program is ting of 1.000 is a good starting point for most condi-
desired, contact the local Lincoln Electric sales repre- tions.
sentative.
To make a weld, the Power Wave needs to know the

desired welding parameters. The Power Feed (PF)
family of feeders communicate settings to the Power
Wave through control cable connection. Arc length,
wire feed speed, arc control, etc. are all communicat-
ed digitally via the control cable.
POWER WAVE 455M

B-7 OPERATION B-7
• WELDING MODE Non Synergic CV:

May be selected by name (CV/MIG, CC/Stick Crisp, This type of CV mode behaves more like a conven-
Gouge, etc.) or by a mode number (10, 24, 71, etc.) tional CV power source. Voltage and WFS are inde-
depending on the Control Box options. Selecting a pendent adjustments. Therefore to maintain the arc
welding mode determines the output characteristics of characteristics, the operator must adjust the voltage to
the Power Wave power source. For a more complete compensate for any changes made to the WFS.
description of the welding modes available in the
Power Wave, see the explanation below.
• ARC CONTROL All CV Modes:

Also known as Inductance or Wave Control. Allows Arc Control, often referred to as wave control, adjusts
operator to vary the arc characteristics from "soft" to the inductance of the wave shape. The wave control
"harsh" in all weld modes. It is adjustable from -10.0 to adjustment is similar to the "pinch" function in that it is
+10.0, with a nominal setting of 00.0 (The nominal set- inversely proportional to inductance. Therefore,
ting of 00.0 may be displayed as OFF on some Power increasing wave control greater than 0.0 results in a
Feed wire feeder control panels). See the Welding harsher, colder arc while decreasing the wave control
Mode descriptions, below, for detailed explanations of to less than 0.0 provides a softer, hotter arc.
how the Arc Control affects each mode. (See Figure A.5)
CONSTANT VOLTAGE WELDING

Synergic CV:
For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft-
ware at the factory. The nominal preprogrammed volt-
age is the best average voltage for a given wire feed
speed, but may be adjusted to preference. When the
wire feed speed changes, the Power Wave automati-
cally adjusts the voltage level correspondingly to
maintain similar arc characteristics throughout the
WFS range.
FIGURE A.5
CURRENT WAVE FORM (CV)
Current
Time
POWER WAVE 455M

B-8 OPERATION B-8
PULSE WELDING The Power Wave utilizes "adaptive control" to com-
pensate for changes in electrical stick-out while weld-
Pulse welding procedures are set by controlling an ing. (Electrical stick-out is the distance from the con-
overall "arc length" variable. When pulse welding, the tact tip to the work piece.) The Power Wave wave-
arc voltage is highly dependent upon the waveform. forms are optimized for a 0.75" (19mm) stick-out. The
The peak current, back ground current, rise time, fall adaptive behavior supports a range of stickouts from
time and pulse frequency all affect the voltage. The 0.50" (13mm) to 1.25" (32mm). At very low or high
exact voltage for a given wire feed speed can only be wire feed speeds, the adaptive range may be less due
predicted when all the pulsing waveform parameters to reaching physical limitations of the welding process.
are known. Using a preset voltage becomes impracti-
cal, and instead the arc length is set by adjusting Arc Control, often referred to as wave control, in pulse
"trim". programs usually adjusts the focus or shape of the
arc. Wave control values greater than 0.0 increase the
Trim adjusts the arc length and ranges from 0.50 to pulse frequency while decreasing the background cur-
1.50, with a nominal value of 1.00. Trim values greater rent, resulting in a tight, stiff arc best for high speed
than 1.00 increase the arc length, while values less sheet metal welding. Wave control values less than
than 1.00 decrease the arc length. 0.0 decrease the pulse frequency while increasing the
background current, for a soft arc good for out-of-posi-
Most pulse welding programs are synergic. As the tion welding.
wire feed speed is adjusted, the Power Wave will (See Figure A.6)
automatically recalculate the waveform parameters to
maintain similar arc properties.
FIGURE A.6
CURRENT WAVE FORM (PULSE)
Current
Time
POWER WAVE 455M

C-1 ACCESSORIES C-1
OPTIONAL EQUIPMENT
FACTORY INSTALLED
Wire Drive Interface Module, K2205-1
FIELD INSTALLED
Work Voltage Sense Lead Kit, K940
Dual Cylinder Undercarriage, K1570-1.
Gas Guard Regulator, K659-1
Coaxial welding Cable, K1796
Cool Arc 40 K1813-1 (115VAC)
Water Flow Sensor, K1536-1
Wire Drive Interface Module, K2205-1
DeviceNet interface Module, K2206-1
COMPATIBLE LINCOLN EQUIPMENT
Any Arc-Link compatible semi-automatic wire feeding

equipment. Specifically, the semi-automatic Power
Feed M family. If the wire drive interface module is
installed the machine is compatible with the Power
Feed 10R wire feeder.
POWER WAVE 455M

D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS
WARNING

• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
• Do not touch electrically hot parts.
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing
out the machine, using a low pressure airstream, to
remove accumulated dust and dirt from the intake and
outlet louvers, and the cooling channels in the
machine.
PERIODIC MAINTENANCE
Calibration of the Power Wave 455M is critical to its
operation. Generally speaking the calibration will not
need adjustment. However, neglected or improperly
calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the cali-
bration of output Voltage and Current should be
checked yearly.
CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the facto-
ry. Generally speaking the machine calibration will not
need adjustment. However, if the weld performance
changes, or the yearly calibration check reveals a
problem, contact the Lincoln Electric Company for the
calibration software utility.
The calibration procedure itself requires the use of a

grid, and certified actual meters for voltage and cur-
rent. The accuracy of the calibration will be directly
affected by the accuracy of the measuring equipment
you use. Detailed instructions are available with the
utility.
POWER WAVE 455M

E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE 455M

charts for both machine and weld performance.
USING THE STATUS LED TO The STATUS LIGHT is a two color light that indicates
TROUBLESHOOT SYSTEM PROBLEMS system errors. Normal operation is a steady green
light. Error conditions are indicated in the following
The Power Wave / Power Feed are best diagnosed as chart.
a system. Each component (power source, user inter-
face, and feed head) has a status light, and when a NOTE: The Power Wave 455M status light will flash
problem occurs it is important to note the condition of green, and sometimes red and green, for up to one
each. In addition, errors displayed on the user inter- minute when the machine is first turned on. This is a
face in most cases indicate only that a problem exists normal situation as the machine goes through a self
in the power source, not what the problem may be. test at power up.
Therefore, prior to cycling power to the system,
check the power source status light for error
sequences as noted below. This is especially
important if the user interface displays "Err 006"
or "Err 100" .
Included in this section is information about the power

source Status LED, and some basic troubleshooting
LIGHT CONDITION MEANING

Status LED is solid green (no blinking). 1. System OK. Power source communicating normally
with wire feeder and its components.
Status LED is blinking green. 2. Occurs during a reset, and indicates the Power
Wave 455M is mapping (identifying) each compo-
nent in the system. Normal for first 1-10 seconds
after power is turned on, or if the system configura-
tion is changed during operation.
Status LED is blinking red and green. 3. Non-recoverable system fault. If the PS Status light
is flashing any combination of red and green, errors
are present in the Power Wave 455M. Read the
error code before the machine is turned off.
Error Code interpretation through the Status light is

detailed in the Service Manual. Individual code digits
are flashed in red with a long pause between digits. If
more than one code is present, the codes will be
separated by a green light.
To clear the error, turn power source off, and back

on to reset.
Status LED is solid red (no blinking). Non recoverable hardware fault. Generally indicates
nothing is connected to the Power Wave 455M wire
feeder receptacle. See Trouble Shooting Section.
Status LED is blinking red. Not applicable.
POWER WAVE 455M

Observe all Safety Guidelines detailed throughout this manual
ERROR CODES FOR THE POWERWAVE

The following is a list of possible error codes that the Power Wave 455M can output via the status light (see
"Troubleshooting the Power Wave / Power Feed System Using the Status LED." If connected to a PF-10/11
these error codes will generally be accompanied by an "Err 006" or "Err 100" on the user interface display.
Error Code # Indication
11 CAN communication bus off. Probably due to excessive number of communication errors.
12 User Interface time out error. UI is no longer responding to the Power Source. The most likely
cause is a fault/bad connection in the communication leads or con-
trol cable.
21 Unprogrammed Weld Mode. Contact the Service Department for instructions on reloading the
Welding Software.
22 Empty Weld Table. Contact the Service Department for instructions on reloading the
Welding Software.
23 Weld Table checksum error. Contact the Service Department for instructions on reloading the
Welding Software.
31 Primary overcurrent error. Excessive Primary current present. May be related to a short in the
main transformer or output rectifier.
32 Capacitor "A" under voltage Low voltage on the main capacitors. May be caused by improper
(Left side facing machine) input configuration.
33 Capacitor "B" under voltage When accompanied by an overvoltage error on the same side, it
(Right side facing machine) indicates no capacitor voltage present on that side, and is usually
the result of an open or short in the primary side of the machine.
34 Capacitor "A" over voltage Excess voltage on the main capacitors. May be caused by improp-
(Left side facing machine) er input configuration.
35 Capacitor "B" over voltage When accompanied by an under voltage error on the same side, it
indicates no capacitor voltage present on that side, and is usually
(Right side facing machine) the result of an open or short in the primary side of the machine.
36 Thermal error Indicates over temperature. Usually accompanied by Thermal LED.

Check fan operation. Be sure process does not exceed duty cycle
limit of the machine.
37 Soft start error Capacitor precharge failed. Usually accompanied by codes 32-35.
The secondary (weld) current limit has been exceeded. When this
41 Secondary overcurrent error
occurs the machine output will phase back to 100 amps, typically
resulting in a condition referred to as "noodle welding"
NOTE: The secondary limit is 570 amps for the standard stud, and
325 amps for all single phase operation.
43 Capacitor delta error The maximum voltage difference between the main capacitors has
been exceeded. May be accompanied by errors 32-35.
49 Single phase error Indicates machine is running on single phase input power. Usually
caused by the loss of the middle leg (L2).
Other Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the PS
Control Board. If cycling the input power on the machine does not
clear the error, try reloading the operating system. If this fails,
replace the control board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER WAVE 455M
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized
is evident when the sheet metal Lincoln Electric Field Service
covers are removed. facility for technical assistance.
Input fuses keep blowing, or input 1. Make certain that fuses or
breaker keeps tripping. breakers are properly sized.
See Installation section of this
manual for recommended
fuse and breaker sizes.
2. Welding procedure is drawing
too much output current, or
duty cycle is too high.
Reduce output current, duty
cycle, or both.
3. There is internal damage to
the power source. Contact an
authorized Lincoln Electric
Service facility.
Machine will not power up (no 1. Make certain that the Power
lights, no fan, etc.) Switch (SW1) is in the “ON”
position.
2. Circuit breaker CB4 (in recon-
nect area) may have opened. If all recommended possible areas
Reset. Also, check input volt- of misadjustments have been
age selection, below. checked and the problem persists,
3. Input voltage selection made contact your local Lincoln
improperly. Power down, Authorized Field Service Facility.
check input voltage reconnect
according to diagram on
reconnect cover.
Thermal LED is lit. 1. Fan thermostat has opened.
Check for proper fan opera-
tion. (Fan should run whenev-
er output power is on.) Check
for material blocking intake or
exhaust louvers, or for exces-
sive dirt clogging cooling chan-
nels in machine.
2. Secondary rectifier or Choke
thermostat has opened. After
machine has cooled, reduce
load, duty cycle, or both.
Check for material blocking
intake or exhaust louvers.
3. DC Bus PC board thermostat
has opened check for exces-
sive load on 40VDC supply.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized Lincoln Electric Field Service Facility for technical assistance.
POWER WAVE 455M

OUTPUT PROBLEMS
Machine won’t weld, can’t get any 1. Input voltage is too low or too
output. (CR1 will not pull in.) high. Make certain that input
voltage is proper, according to
the Rating Plate located on the
rear of the machine.
2. If the Thermal LED is also lit,
see “Yellow Thermal LED is Lit”
section.
3. Primary current limit has been
exceeded. Possible short in out-
put circuit. Turn machine off.
Remove all loads from the out-
put of the machine. Turn back
on. If condition persists, turn
power off, and contact an autho-
rized Lincoln Electric Field
Service facility.
4. This problem will normally be
accompanied by an error code.
Error codes are displayed as a
series of red and green flashes by If all recommended possible areas
the status light. See of misadjustments have been
"Troubleshooting the Power Wave checked and the problem persists,
/ Power Feed System Using the contact your local Lincoln
Status LED" section of this text. Authorized Field Service Facility.
Machine often “noodle welds” (out- 1.Secondary current limit has been
put is limited to approximately 100 exceeded, and the machine has
amps) when running a particular phased back to protect itself.
procedure, especially a procedure 2. Adjust procedure or reduce load
with high WFS. to lower current draw from the
machine.
3. A single phase input (loss of L2)
will reduce the secondary cur-
rent limit from 570 Amps to 325
Amps.
CAUTION
POWER WAVE 455M

OUTPUT PROBLEMS
Machine won’t produce full output. 1. Input voltage may be too low,
limiting output capability of the
power source. Make certain that
the input voltage is proper,
according to the Rating Plate
located on the rear of the
machine.
2. Input may be “single phased”.
Make certain the input voltage is
proper on all three Input lines.
3. Secondary current or voltage not
be properly calibrated. Check
values displayed on the Power
Feed 10/11 verses readings on
an external meter.
Auxiliary receptacle is “dead” no 1. Circuit breaker CB2 (on case

auxiliary voltage . front) may have opened. Reset.
2. Circuit breaker CB4 (in recon-
nect area) may have opened.
Reset. If all recommended possible areas
General degradation of the weld 1.Check for feeding problems, bad of misadjustments have been
performance connections, excessive loops in checked and the problem persists,
cabling, etc. contact your local Lincoln
2. Verify weld mode is correct for Authorized Field Service Facility.
processes.
3. The power source may require
calibration.
4. Check the actual current dis-
played on the Power Feed 10
vs. actual current measured via
external meter.
5. Check the actual voltage dis-
played on the Power Feed 10
vs. actual voltage measured via
external meter.
6. Check the actual WFS displayed
on the Power Feed 10 vs. actual
WFS measured via external
meter.
Excessively long and erratic arc. 1. Check for proper configuration

and implementation of voltage
sensing circuits.
CAUTION
POWER WAVE 455M

F-1
DIAGRAMS
POWER WAVE 455M

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2
DIAGRAMS
POWER WAVE 455M

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
F-2
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-3 CONNECTION DIAGRAM F-3
Connection Diagram Semi-automatic "Simple System"
(Electrode Positive, CV/Pulse Configuration shown)
POWER WAVE
TO WIRE
WORK FEEDER
CONTROL CABLE K1543
POWER WAVE 455M

F-4
DIMENSION PRINT - POWER WAVE 455M
19.90
19.16
9.48 14.62
22.63
26.10
23.12 23.51
DIAGRAMS
POWER WAVE 455M

12.35
19.00 32.88
11-14-97
M18241
F-4
NOTES
POWER WAVE 455M

● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION ● Aislese del trabajo y de la tierra.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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RETURN TO MAIN MENU

Safety Depends on You

Copyright © 2006 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

5.e. Read and understand the manufacturer’s instructions for this

5.f. Also see item 1.b.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

5. Toujours porter des lunettes de sécurité dans la zone de

for selecting a QUALITY product by Lincoln Electric. We want you

Please Examine Carton and Equipment For Damage Immediately

On-Line Product Registration

208/230/460/575V - 60HZ. 450A@38V.100% 58/53/25/22

75 VDC 5 - 570A 0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. - 40 VDC AT

208/50/60HZ 4(25) 6(16) 110

TEMPERATURE RANGES STORAGE TEMPERATURE RANGE

* Earlier models used 10 amps circuit breaker.

POWER WAVE 455M

Do not use Power Waves in outdoor environments.

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

VOLTAGE =220-230V VOLTAGE = 440-460V VOLTAGE = 550-575V

WORK When operating with electrode polarity negative the

POWER WAVE 455M

----------------------------------------------------------- Due to the flexibility of the platform the configuration may

DIP switch. information to be passed at very high speeds between

components (nodes) in the system. The system requires

only two wires for communication, and because of its

4. Using a pencil or other small object,

the network in any order, thus simplifying the system set-

the ON position if the work sense lead

POWER WAVE 455M

SINGLE HEAD FEEDER DUAL HEAD FEEDER

POWER WAVE POWER WAVE

SINGLE HEAD BOOM FEEDER

SINGLE HEAD BOOM FEEDER

POWER WAVE 455M

POWER WAVE 455M

POWER WAVE 455M

COMBINATION HARD AUTOMATION APPLICATION

POWER WAVE 455M

System that is NOT "Auto Mappable"

DUAL HEAD BOOM FEEDER

WELDING WITH MULTIPLE POWER CONTROL CABLE SPECIFICATIONS

Every welding gun requires a separate shielding gas

Do not attempt to supply shielding gas for two or more

If an anti-spatter system is in use then each gun must

Connect All Work

Connect All Welding

POWER WAVE 455M

TABLE 5 CONTROL BOARD (DIP Switch Location)

DIP SWITCH SETTINGS AND LOCATIONS

CONTROL BOARD DIP SWITCH:

POWER WAVE 455M

ELECTRIC SHOCK can kill.

FUMES AND GASES can be dan-

WELDING SPARKS can cause fire

ARC RAYS can burn.

Observe additional guidelines detailed in the begin-

POWER WAVE 455M